Inductor having high current coil with low direct current resistance

Abstract

An inductor and method for making the same are provided. The inductor includes a coil formed from a conductor and having a serpentine shape. The coil may have an “S”-shape. The coil has two leads extending from opposite ends of the coil. An inductor body surrounds the coil and portions of the leads. The leads may be wrapped around the body to create contact points on the exterior of the inductor.

What is claimed is: 
     
       1. An electro-magnetic component comprising:
 a coil formed from a flat conductive material, the conductive material having a width greater than a thickness of the conductive material, wherein the coil extends along an at least partially curving path that does not completely encircle a central area of the coil; 
 a first lead extending from a first end of the coil; 
 a second lead extending from a second end of the coil; 
 a body pressed around the coil and portions of the first lead and the second lead leaving an exposed portion of the first lead and an exposed portion of the second lead, the body comprising a front surface and an opposite back surface, a top surface and an opposite bottom surface, and a first side surface an opposite second side surface, wherein a depth of the body extends between the front surface and the back surface and a height of the body extends between the top surface and the bottom surface, the height being greater than the depth, and wherein the coil is positioned such that the width of the conductive material extends along the depth of body; 
 at least a portion of the exposed portion of the first lead positioned so as to extend along the bottom surface of the body; and 
 at least a portion of the exposed portion of the second lead positioned so as to extend along the bottom surface of the body. 
 
     
     
       2. The electro-magnetic component of  claim 1 , wherein the coil comprises a portion curving toward the top surface of the body. 
     
     
       3. The electro-magnetic component of  claim 2 , wherein the portion of the coil curving toward the top surface of the body curves outwardly and away from a central area of the coil. 
     
     
       4. The electro-magnetic component of  claim 1 , wherein the coil and leads are formed from a unitary piece of conductive material. 
     
     
       5. The electro-magnetic component of  claim 1 , wherein the first lead has a width that is less than the depth of the body, and the second lead has a width that is less than the depth of the body. 
     
     
       6. The electro-magnetic component of  claim 1 , wherein a shape of the coil is configured to optimize a path length of the coil to fit a space available within the body of the electro-magnetic component while minimizing resistance and optimizing inductance. 
     
     
       7. The electro-magnetic component of  claim 1 , wherein the coil is formed by stamping, bending, cutting, folding or a combination thereof. 
     
     
       8. The electro-magnetic component of  claim 1 , wherein at least a portion of the coil curves inwardly toward a central vertical axis of the body running between the top surface and the bottom surface of the body. 
     
     
       9. The electro-magnetic component of  claim 1 , wherein the coil comprises a first area positioned adjacent to the first side surface of the body and a second area curving inwardly toward a central vertical axis of the body running from the top surface to the bottom surface of the body, and the coil comprises a third area positioned adjacent to the second side surface of the body and a fourth area curving inwardly toward the central vertical axis of the body. 
     
     
       10. The electro-magnetic component of  claim 1 , wherein the coil has a first flat surface facing the front surface of the body and a second flat surface facing the back surface of the body, and wherein no part of the coil is wound over or under another part of the coil along the depth of the body. 
     
     
       11. An electro-magnetic component comprising:
 a coil formed from a flat conductive material, the conductive material having a width greater than a thickness of the conductive material; 
 a first lead extending from a first end of the coil; 
 a second lead extending from a second end of the coil; 
 a body pressed around the coil and portions of the first lead and the second lead leaving an exposed portion of the first lead and an exposed portion of the second lead, the body comprising a front surface and an opposite back surface, a top surface and an opposite bottom surface, and a first side surface an opposite second side surface, wherein a central vertical axis of the body runs from the top surface to the bottom surface of the body, and wherein a depth of the body extends between the front surface and the back surface and a height of the body extends between the top surface and the bottom surface, the height being greater than the depth; 
 the coil positioned within the body such that the width of the conductive material extends along the depth of body, wherein the coil has a first flat surface facing the front surface of the body and a second flat surface facing the back surface of the body, the coil following an at least partially curving path extending between the first end of the coil and the second end of the coil such that no part of the coil is wound over or under another part of the coil along the depth of the body, wherein a first portion of the coil curves inwardly from the first end of the coil toward the central vertical axis, and wherein a second portion of the coil curves inwardly from the second end of the coil toward the central vertical axis of the body; 
 at least a portion of the exposed portion of the first lead positioned so as to extend along the bottom surface of the body; and 
 at least a portion of the exposed portion of the second lead positioned so as to extend along the bottom surface of the body. 
 
     
     
       12. The electro-magnetic component of  claim 11 , wherein the coil comprises a portion curving outwardly away from a central area of the body. 
     
     
       13. The electro-magnetic component of  claim 11 , wherein the coil and leads are formed from a unitary piece of conductive material. 
     
     
       14. The electro-magnetic component of  claim 11 , wherein the first lead has a width that is less than the depth of the body, and the second lead has a width that is less than the depth of the body.